specialty chemicals & life science -...

© Copyr i gh t 2015 O SIs o f t , LLC .

Specialty

Chemicals & Life

Science

Presented by: Michael Purcell


Challenges

• Management• Cost• Sustainability

Energy/Utilities

• Facilities/Manufacturing Shop Floor

• Raw Material Usage

• Metering

• Managing Costs• Understanding Usage Peaks/Patterns

• Optimize usage periods/sources/pricing

• Understand Usage Demands per recipe/product


Challenges

• cGMP• Batch/Lot

Analysis• Environmental

Compliance

• Out of the box functionality

• 450+ off the shelf Interfaces

• Supports Regulatory Compliance• Audit Trail

• 21 CFR part 11

• ISA-88 /95

• Environmental Reporting for Sustainability


Challenges

• Data Normalization

• Process Stability

• Visibility

Standardization

• Normalize Data

• Standard Equipment Models

• Naming Conventions

• Consistent Visualization & Reporting

• Consistent view from product/process development through manufacturing


Challenges

• Batch/Lot Reporting

• Operational Excellence

• Process Optimization

• Real time decisions

Data Access

• Situational awareness enables real time decision making

• Secure/Enterprise-wide access to real time data

• Multiple Options for End Users

• Mobile Devices

• Thick & Thin Client Tools

• Strong Partner Community


Challenges

• MES• BES• Disparate

Automation• S95

Data Integration

• Enterprise Manufacturing Intelligence (EMI) Infrastructure

• MES Interfacing Strategies

• PAS-X, Simatic IP, Syncade, and more

coming

• 450+ off the shelf Interfaces

• DCS, BES, SCADA, PLC, MES, LIMS, etc.

• Smart/Self Configuring Connectors


“Enterprise manufacturing intelligence (EMI) software is a suite of software

applications that integrates a company's manufacturing data from multiple

sources to aid in reporting, analysis, visual summaries and passing

data between enterprise-level and plant-floor systems. The combined

data can be given a new structure to make locating information easier. ”http://searchmanufacturingerp.techtarget.com/definition/manufacturing-intelligence-software

Copyright 2011 MESA North American Conference

Enterprise Manufacturing Intelligence

http://searchmanufacturingerp.techtarget.com/definition/manufacturing-intelligence-software


• Aggregation– data from many sources, including databases.

• Contextualization– flexible data model, including ISA-S95 standard and others

– link data to specific batches, equipment, and events

• Analysis– analyze data across production sites

– real-time ad hoc analysis and reporting

• Visualization– configurable visual summaries, including dashboards

– real-time alerts and actionable insights

• Data, Event and Information Propagation– line-of-business integration

– plant-floor to enterprise systems such as SAP, or vice versa

EMI - Core Functions


ISA S95

ISA S95 Architecture

Level 4: ERP

Level 3: MES

Level 2

Level 1

Manufacturing Operations

Management

Batch

Control

Continuous

Control

Discrete

Control

Business Planning & Logistics

SC

AD

A /

PL

C / D

CS

Level 0: Equipment

L4 – Establishing the basic plant schedule – production, material

use, delivery, and shipping. Determining the inventory levels.

Time Frame: Months, weeks, days, shifts

L3 – Work flow / recipe control, stepping the process through

states to produce the desired end products. Maintaining records

and optimizing the production process.

Time Frame: Shifts, hours, minutes, seconds

L2 – Monitoring, supervisory control and automated control of the

production processes

L1 – Sensing the production process, manipulating the

production process

© C o py r i ght 2015 OS Iso f t , LLC .


ISA S95

Real Time Data Infrastructure: A Key Enabler

Level 3: MES

Level 4: ERP

Real-Time Data InfrastructureCommon Data Presentation Layer

Event Frames& Batch

Electronic Work Instructions

Process data, Building automation data,

Alarm & Events

PI System

PI

Server

Time-Series

PI AF

Assets

PI EF

Downtime

Excursions

Batch

Events

ReferencedData

Data Access

Level 2

Level 1

Level 0: Equipment

Batch

Control

Continuous

Control

Discrete

Control

SC

AD

A /

PL

C / D

CS

PI Data Access


ISA S95

Level 3: MES

Level 4: ERP

Real-Time Data InfrastructureCommon Data Presentation Layer

Event Frames& Batch

Electronic Work Instructions

Process data, Building automation data,

Alarm & Events

ReferencedData

Data Access

PI System

PI

ServerTime-Series

PI AF

Assets

PI EF

Events

PI Data Access

The PI System Integration with Analytics

Analysis/Reporting Services

MII

http://www.oracle.com/index.html

http://www.oracle.com/index.html


Productiondata

collection

Productionexecution

management

Productionresource

management

Productiondispatching

Productiontracking

Productionperformance

Detailedproductionscheduling

Productionschedule

Productdefinition

management

Production level 1-2 functions

ProductionPerformance

analysis

Productioncapability

Productdefinition

Equipment and process

specific production rules

Equipment and

processspecific data

Operational

responses

Operational

commands

Functions that the PI System

should participate in

Functions outside of the

PI System


Interfacing Strategy – Current/Future

Process Control System(s)

MES

Production Data Collection

(Continuous, Batch,

Equipment)

Common Plant

Floor

Presentation

Layer to

support

Execution

Electronic Work

Instruction (EWI),

MES

Synchronization

CURRENTRecipe Param Downloads /

Operational Commands &

Synchronization

PI Server

Standard PI

Interfaces (450+),

BES Interfaces

PI Server, PI AF,

PI Data Access, HA

MES

Interfaces

OptionOperational Commands &

SynchronizationRecipe Param Downloads

FUTURE Operational Commands &

Synchronization & Recipe Param Downloads

ERPEMI Integration

EMI Integration


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